G600 Series

Operation Manual

Worldwide Manufacturer of Gas Detection Solutions

TABLE OF CONTENTS
1. Description ................................................................................................................. 3
2. Principle of measurement ....................................................................................... 4
2.1 Catalytic combustion .............................................................................................. 4
2.2 Thermal conductivity.............................................................................................. 4
3. Construction of the instrument.............................................................................. 5
4. Use of the instrument .............................................................................................. 8
4.1 Commissioning ........................................................................................................ 8
4.1.1 Control of the operational voltage.................................................................... 8
4.1.2 Checking the mechanical zero............................................................................ 9
4.1.3 Checking the electrical zero................................................................................ 9
4.2 Modes of operation .............................................................................................. 10
4.2.1 Measurement range 0 to 100% volume .......................................................... 11
Pump mode ................................................................................................................. 11
4.2.2 Measurement in the range of 0 to 5% volume (0 to 100% LEL respectively)
................................................................................................................................. 12
Diffusion mode ............................................................................................................ 12
Pump mode ................................................................................................................. 13
4.2.3 Micro range approximately 0 t0 8,000 ppm (G 634 only) ............................... 13
Pump mode ................................................................................................................. 14
4.3 Alarm....................................................................................................................... 14
4.4 Display error / sensor poisons.............................................................................. 15
Oxygen deficiency ....................................................................................................... 15
Sensor poisons (catalytic combustion sensors) ....................................................... 15
4.5 Distinction between methane (natural gas/town gas) and propane/butane
(technical gas) ........................................................................................................ 16
5. Technical data .......................................................................................................... 18
6. Test and approvals .................................................................................................. 20
7. Maintenance............................................................................................................. 20
7.1 Charging of battery black .................................................................................... 21
7.2 Calibration and adjustment ................................................................................. 23
7.2.1 Calibration of the mechanical zero.................................................................. 24
7.2.3 Sensitivity calibration ........................................................................................ 26
7.3 Gas alarm thresholds............................................................................................. 28
7.4 Grit and fine dust filter......................................................................................... 29
7.5 Pump control ......................................................................................................... 30
7.6 Maintenance schedule .......................................................................................... 31
8. Malfunctions ............................................................................................................ 33
9. Accessories ............................................................................................................... 34
10. Ordering information ........................................................................................... 36
Accessories ................................................................................................................... 37

1. Description
The EXOTECTOR measures and monitors mixtures of combustible
gases and vapors in air below the LEL range. An additional range
makes it possible to measure methane in the range of up to 100
% volume.
The different gases and ranges tested are:
Gas
Range
Methane 0 to 5% CH4, 0 to 100% LEL, and 0 to 100 % volume
Propane 0 to 100% LEL
Nonane
0 to 100% LEL
The second range 0 to 100 % volume
Makes it possible to measure gas concentrations above the LEL
e.g. such as required by gas suppliers, fire brigades, or when
searching for leakages in gas pipelines or when bleeding gas
pipelines.
A third range 0 to 8,000 ppm (micro range, G 634 P) is suitable for
leak detection when gas concentrations are very low.
A large rotary switch, which is easy to use is situated on the
front of the device. This serves to turn the EXOTECTOR on and
off and to select the measurement range. The EXOTECTOR has an
adjustable alarm threshold in the range 0 to 5 % volume (O to
100 % LEL respectively).
If the gas concentration exceeds the set alarm threshold, the
device emits an alarm. In the case of an alarm the large red
alarm lamp is activated and in addition the acoustic alarm signal
emits a piercing sound. The gas alarm is alternatively latched or
not latched. If the alarm is latched, it can only be reset below
the alarm threshold. If battery voltage is insufficient, an alarm is
also raised. The small size, the easy handling and the
combination of 2 respectively 3 ranges make the EXOTECTOR
extremely suitable for a variety of applications.
3

Due to its rechargeable NiCd accumulator the device can

monitor the ambient air for combustible gases and vapors for
more than 10 hours in diffusion mode.
The EXOTECTOR is equipped with a high-performance electric gas
pump which allows measurements to be made in inaccessible
areas such as containers and manholes using sampling lines and
telescopic probes.
2. Principle of measurement
2.1 Catalytic combustion
In the ranges
0 to 5 % volume (O to 100 % LEL resp.)
0 to 8000 ppm (micro range, G 634 P)
the EXOTECTOR operates according to the principle of catalytic
combustion.
The inflammable mixture of combustible gas and vapor in air
diffuses through a flame arrestor into the combustion chamber
or it is supplied by the sampling pump. In the combustion
chamber there are an active sensor (detector) and an inactive
sensor (compensator). The gas and vapor mixture is burnt at the
preheated active sensor. The temperature increase due to
combustion results in a proportional change in the electrical
resistance, unbalancing the measurement bridge circuit. The
bridge signal is amplified and is used for indication and alarm. If
various combustible gases and vapors are present in the gas
sample, e.g. methane and propane, they are measured and
indicated as one gas by the EXOTECTOR.
2.2 Thermal conductivity
For the measurement of high gas concentrations in the range:
0 to 100 % volume the EXOTECTOR operates according to the
measurement principle of thermal conductivity. For this
method of measurement the different thermal conductivities
4

of gases are used. In the combustion chamber of the EXOTECTOR

are, in addition to the catalytic combustion sensor, two thermal
conductivity sensors. The first sensor is in a sealed air-filled
chamber (reference sensor) while the second sensor (signal
sensor) comes into contact with the gas to be measured by
means of diffusion or using the pump.
The signal and the reference sensors are both heated to
working temperature. According to the thermal conductivity of
the gas the signal sensor is either cooled down or heated up and
compared to the reference sensor, which does not come into
contact with the gas, and the difference is indicated by the
EXOTECTOR (e.g. the thermal conductivity of methane and
hydrogen is positive).
The thermal conductivity sensor integrated in the EXOTECTOR
has been specially developed by GfG and has special features.
Gases like methane and hydrogen for example have a positive
conductivity when compared to air and thus result in a positive
signal (reading) on the EXOTECTOR
However, gases like propane, butane, and ethane etc., which
(according to their thermal conductivities) have a negative
thermal conductivity signal in comparison to air, are also shown
as positive by the EXOTECTOR. Therefore, they do not lead to a
reduction of the measurement reading. The negative signal
behavior of carbon dioxide (CO2) has also been markedly
reduced compared to other sensors (e.g. 50 % volume CH4 + I 0
% volume C02 in air result in a reading of 48 - 49 % volume CH4).
3. Construction of the instrument
Figure 1 shows the EXOTECTOR G 634 and the individual parts for
the use of the instrument.

1.

2.

3.
4.
5.

6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Measurement range selection switch

Off: instrument is not in use

% volume: Instrument is operating in the range 0

to 100 % volume

LEL: Instrument is operating in the range 0 to 5 %

volume (O to 100 % LEL respectively)

Micro Instrument is operating in the micro range (O to

8,000 ppm)
Dual function switch

Switch for battery charge level

Alarm reset
Sampling pump switch
Charging socket
Adjustment potentiometers for maintenance

Z.P-LEL - zero point potentiometer 0 to 5 % volume (0 to

100 % LEL respectively)

Z.P-% volume - zero point potentiometer 0 to 100 %

volume

Cal-LEL - Span potentiometer 0 to 5 % volume (O to 100

% LEL respectively)

Cal-% volume - span potentiometer 0 to 100 % volume

Zero point potentiometer for the micro range
Adjustment screw for the mechanical zero
Display
Battery charge range
Range: 0 to 8,000 ppm (micro)
Range: 0 to 5 % volume (O to 100 % LEL respectively.)
Range: 0 to 100 % volume
Operation LED
Alarm LED
Intake for sampling line
Measurement chamber intake for diffusion mode
Measurement chamber cover cap

4. Use of the instrument

4.1 Commissioning
Commissioning should be done in an atmosphere free of
interfering gases.
4.1.1 Control of the operational voltage
Be sure to check the charge level of the integrated NiCdaccumulator before and after use of the EXOTECTOR (see figure
2)

Switch the measurement range selection switch to the %

volume or LEL position
Green operation LED lights up
Press the charge control/reset switch

The indicator is in the yellow battery range - the battery must

be recharged.
4.1.2 Checking the mechanical zero
The indicator of the measuring instrument must be in the zero
tolerance field near the zero mark when off.
4.1.3 Checking the electrical zero

Switch the range switch to the position 0 to 100 % volume

the indicator should move into the zero tolerance range
within 15 seconds

Switch the range switch to the position 0 to 5 % volume (O

to 100 % LEL respectively)
The indicator should move into the zero tolerance range within
15 seconds.
9

If the instrument operates as indicated above, it is ready for use.

If this is not the case, the instrument is not ready for use and
must be inspected.
4.2 Modes of operation
According to the type of model the EXOTECTOR provides up to 3
measurement ranges:

Range: 0 to 100 % volume (G 624, G 634)

Range: 0 to 5 % volume (O to 100 % LEL respectively) (G 624

P, G 634 P)

Range: 0 to ca. 8000 ppm (micro) (G 634 P)

In addition to this, the gas sample reaches the sensor either by
means of diffusion or by means of the integrated gas sampling
pump. Usually, we recommend (the local conditions and the
company regulations must be observed), especially before
entering manholes, sewers, or hazardous areas, to begin with
measurements in the highest possible range and working down
to low range. Furthermore, the integrated gas sampling pump
makes it possible to take samples by means of a telescopic

10

suction probe or sampling lines before entering hazardous

areas.
4.2.1 Measurement range 0 to 100% volume
Due to the switching sequence of the EXOTECTOR it is necessary
to always start with the measurement range 0 to 100 % volume.
The reasons for this result on one hand from the safety
philosophy (see chapter 4.2) and on the other hand the catalytic
combustion sensor is protected from high gas concentrations
and thus the life span of the sensor is increased.
The measurement range 0 to 100 % volume is mainly used for
the detection of gas before entering manholes and sewers or
hazardous areas, the search for leakages in underground gas
pipelines, the measurement of high gas concentrations when
filling gas tanks and pipelines with gas.
In practice, these measurement functions are nearly always
executed by means of the electrical gas sampling pump in
connection with adequate sampling lines and telescopic suction
probes.
Pump mode
For the exact measurement of high gas concentrations in pump
mode it is recommended to close the diffusion opening by
means of the cover cap.

Turn range switch to position 0 to 100 % volume

Short acoustic and visible operational alarm

Press pump switch - the gas sampling pump is activated

supplying the gas sample to the sensors.
During pump mode the thermal conductivity sensor is
continuously in operation allowing changes in the gas
concentration to be read immediately from the meter. If
sampling tubes and telescopic sampling probes are used, the

11

suction time (tp) required by the pump to supply the gas to the
sensor must be taken into consideration.

The suction time for 1 m sampling line and telescopic

suction probe (1.36 or 1.92 m) can be up to 15 seconds tp.

Extending the sampling line always means increasing the

suction time by approx. 4 seconds per meter.

If measurement is finished, the pump switch must be

released and the range switch must be turned to the
position OFF.
In order to protect the sensors in the pump mode from the
suction of dust, humidity, and water we recommend to use a
special filter.
If the gas concentration is lower than 5 % volume (O to 100 %
LEL respectively), measurement must be continued in the range
of 0 to 5 % volume (O to 1 00 % LEL respectively).
4.2.2 Measurement in the range of 0 to 5% volume (0 to
100% LEL respectively)
Diffusion mode
If the EXOTECTOR is used in diffusion mode for continuous
monitoring of gas hazards, the cover cap (picture 1, pos. 17)
must be removed from the diffusion opening.
The EXOTECTOR must be switched on in fresh air before being
used for the measurement of inflammable gases.

Turn range switch from position 0 to 100 % volume to 0 to 5

% volume (0 to 100 % LEL respectively)
Thus, it is guaranteed that the latched alarm also reacts, if the
gas concentration exceeds the LEL. It is not allowed to turn the
alarm signal off, if high gas concentrations are present.
The EXOTECTOR monitors the ambient air for combustible gases
and vapors for approx. 10 hours, if the battery is fully charged.

12

Pump mode
Same procedure as in diffusion mode.

Press pump key

The gas sampling pump operates and supplies the gas sample to
the sensor. In order to complete the measurement, release the
pump key. The other instructions given in chapter 4.2.1 pump
mode still remain valid.
4.2.3 Micro range approximately 0 t0 8,000 ppm (G 634 only)
The micro range is used for the measurement of lowest gas and
vapor concentrations in the ppm range. In the pump mode the
micro range makes it possible to detect leakages e.g. in gas
pipelines and flanges, but in the diffusion mode it can also be
used for personal monitoring of combustible gases and vapors.
The range 0 to 8,000 ppm is not scaled. Using the regulating
switch for the adjustment in the micro range a fine tuning can
be made before each measurement. The fine tuning does not
change the set alarm threshold. If gas concentrations exceed
the set alarm threshold, the EXOTECTOR raises an acoustic and
visible alarm.
Diffusion mode

Turn range switch from position 0 to 5 % volume (O to 100

% LEL) to micro range.

If necessary, execute fine tuning of the zero point with the

zero point regulating switch. In that case, the position of
the instrument (vertical, 45" or horizontal) must be taken
into account, because in the micro range a change of
position can have a slight effect on the measurement range
pointer.
The EXOTECTOR monitors the ambient air for lowest
concentrations of combustible gases and vapors for
approximately 10 hours.

13

Pump mode

Same procedure as in diffusion mode

Press pump key - the gas sampling pump operates supplying

the gas sample to the sensor.
Due to the suction of gas by means of a powerful electrical gas
sampling pump slight oscillations of the range indicator may be
caused by the cooling of the sensor and the influence of the
position.
The other instructions given in chapter 4.2.1 Pump mode still
remain valid.
4.3 Alarm
If an alarm is raised, the large red alarm-LED lights up and a
permanent acoustic alarm is emitted.
Gas alarm
The EXOTECTOR has an adjustable alarm threshold in the range 0
to 5 % volume (0 to 100 % LEL respectively). The alarm threshold
is factory set at 20 % LEL (methane LEL = 5 %, alarm threshold 1
% volume*). An acoustic and optical alarm is emitted if the gas
concentration exceeds the alarm threshold.
This is valid for both measurement ranges: - 0 to 5 % volume (0
to 100 % LEL respectively) - micro range approx. 0 to 8,000 ppm
Depending on the type of device the alarm is latching or not
latching. If the alarm is latching, the dual function switch (figure
1, point 2) is to be pressed shortly for alarm reset.
Battery alarm
The battery charge level of the EXOTECTOR is continuously
monitored. If the charging voltage reaches the discharge level,
an acoustic and optical alarm is emitted. The battery alarm
cannot be turned off.
If battery alarm is raised, the EXOTECTOR can be used for another
10 minutes approximately. After 10 minutes the measured
14

values are no longer reliable. The battery capacity can be

checked at any time by pressing the switch for the battery
charge level. If battery alarm is raised, it is recommended to
switch the EXOTECTOR off and to recharge the battery.
4.4 Display error / sensor poisons
Oxygen deficiency
It is to be taken into consideration that the accurate
measurement of gas and/or vapor concentrations in both
measurement ranges below 5 % volume (100 % LEL respectively)
cannot be carried out exactly, if the oxygen concentration is at
the same time less than 5 % volume. In this case the catalytic
combustion sensor does not have the required oxygen for the
"catalytic combustion". In practice, this measurement task is
very rare e.g. it is used for the inerting of pipelines and
containers. Under these circumstances, it is recommended to
carry out the measurement with another measuring principle
such as thermal conductivity - range 0 to 100 % volume or to use
a bypass for the suction of air and to effect the measurement
according to the principle of catalytic combustion.
Sensor poisons (catalytic combustion sensors)
Certain substances known as sensor or catalyst poisons affect
the sensor in its signal behavior. The "sensitivity" that means the
ability of the sensor to release signals is reduced. These
substances are for example sulphur, lead or silicium compounds.
In addition, the halogenated hydrocarbons must be mentioned
because they have a corrosive effect on the sensor. Usually,
these substances are rarely found and in small concentrations
only.
If these substances occur more often, calibration, that means
examination of the sensitivity of the sensor must be carried out
before and after each measurement (see 7.2.3). In addition, as a
preventive measure we recommend to take the gas sample by
15

means of an electrical pump and a sampling line and to put a

carbon filter into the intake (e.g. a charcoal filter tube), if silicide
compounds are present in the gas sample.
This carbon filter retains the silicide compounds, but does not
retain methane, hydrogen, and other gases. It must be taken
into consideration that propane and butane for example are
absorbed by the carbon filter. Therefore, a lower reading has to
be taken into account.
4.5 Distinction between methane (natural gas/town gas)
and propane/butane (technical gas)
In manholes and sewers methane (natural gas) as well as
propane/butane (technical gas) can be found. It is not possible to
distinguish between the gases only by means of the display of
the EXOTECTOR. However, the GfG charcoal filter tube makes it
possible to distinguish between methane and propane/butane.
The distinction is possible because the GfG charcoal filter tube
retains propane and butane in concentrations up to approx. 15
% volume, but methane (natural gas) is practically not retained
at all.
Instructions for Use
The definition of the type of gas can be made as follows: first,
the GfG charcoal filter tube must be prepared. For this, the tips
of the tubes must be removed by means of the enclosed file.

The first measurement is to be carried out by means of the

electrical pump as usual without using the charcoal filter
tube
For the second measurement the open GfG charcoal filter
tube is to be inserted into the sampling line and then a
Second gas sample has to be taken through the filter tube
and the sampling line.

Typical reading for gas concentrations in the LEL range:

16

If the reading does not change, only methane is present in

the gas sample.
If the reading decreases, a propane/butane/methane
mixture is present.
If the reading shows "O", only propane or butane are
present. The GfG charcoal filter tubes are not suited for
multiple use.

17

5. Technical data
Range:

0 to 1 00 % volume
0 to 5 % volume (O to 100 % LEL respectively)
0 to 8,000 ppm (micro range)

Measuring principle:

0 to 1 00 % volume - thermal conductivity, 0 to 5

% volume (O to 100 % LEL respectively), and 0 to
8,000 ppm - catalytic combustion

Display:

Analog meter

Scale graduation:

Range 0 to 8,000 ppm yellow field

Range 0 to 5 % volume (O to 1 00 % LEL
respectively.)
0 to 1 % volume green field
1 to 5 % volume yellow field - range
to 100 % volume
0 to 5 % volume yellow field
5 to 15 % volume red field
15 to 100 % volume yellow field

Display accuracy:
Range 0 to 8,000 ppm Leakage detection, quantitative indication only
< 4 % of full scale 0 to 5 % volume
Range (O to 100 %
volume respectively) < 2 % of full scale
Range 0 to 100 %
(under normal conditions)
volume respectively)
Range 0 to 100 %
volume
Reading accuracy:
Range
Better +/- 0.2 % volume 0 to 5 % volume
Range
Approximately 1.0 % volume 0 to 100 % volume
Operating
temperature:

-20 C to < + 55 C

18

Storage temperature: -40 C to + 600 C

recommended + 5 to 25 C
Approved
temperature range:

20 C to < + 55 C (approval)

Humidity range:

Can be used within the range of 35 % to 95 %

r.h.

Gas sampling:

Diffusion
Diaphragm pump (approximately 0.5
l/minutes)

Response time:
(20 % of full scale)

t2o:- diffusion approx. 5.5 s for methane

(20 % of full scale) pump 0 to 100 % LEL
approximately 4.5 seconds 0 to 1 00 %
volume approximately 2.5 seconds for
methane

Response time:

t90: - diffusion (90 % of full scale)

approximately 48 seconds for methane
Pump 0 to 100 % LEL approximately 8.5
seconds 0 to 100 % volume approximately 6.5
seconds for methane

Alarm thresholds:

One alarm threshold, adjustable within 0.3 to 5

% volume, latching or not latching (factory-set
at 1 % volume / 20 % LEL)

Alarm:
Optical
Acoustic

1 large red LED, permanent light Piezoelectric

alarm, continuous tone

Power supply:

Rechargeable NiCd accumulator

Operating time:

With a fully charged battery approx. 10 hours

without alarm and use of the pump

19

Voltage control of
the accumulator:

By means of a push button, acoustic, and optical

alarm in case of discharged battery

Housing material:

Polyamide, antistatic, impact proof, surface

resistance <100 Ohm

Dimensions:

90 x 130 x 45 mm

Weight:

Approximately 800 gram

Class of protection:

(EX is G5)

BVS-Approval:

T 6725

6. Test and approvals

The EXOTECTOR type G 624, G 634 has been ex-approved.
The construction of the intrinsically-safe electrical device
EXOTECTOR has been approved for use in potentially explosive
areas by the certificate of the BVS.
Approval (EX) i,s G5
BVS-No.: T 6725
The display accuracy and the test for use in practice according
to ZH 1 08 and ZH 108.1 respectively. have been approved.
7. Maintenance
The EXOTECTOR does not need special maintenance.
Nevertheless, depending on the conditions of use, the battery
block must be charged regularly and the electrical pump and
the zero point must be checked at regular intervals.
In addition, the device must be calibrated at regular intervals,
for this calibration the GfG service is at your disposal. We
recommend a maintenance contract with an interim inspection
every six months and an annual basic inspection.
20

7.1 Charging of battery black

Depending on the mode of operation, the capacity of a fully
charged battery block (NiCd-accumulator) is sufficient for
continuous use of approximately 10 hours. If measurements are
carried out by means of the electrical gas pump or if an alarm is
raised, the operational time is reduced due to higher energy
consumption. Insufficient battery capacity is indicated by an
acoustic and visible alarm. It is possible to check the actual
capacity of the battery block at any time.
The operating voltage check must be carried out as follows: turn
the measurement range switch to % volume or LEL position
press the charge level/reset switch the indicator in the battery
control range must move to right side full scale and more

The battery is fully charged (picture 3) the indicator is in the

middle of the green battery control range

The battery is charged to 50-60 % (picture 4)

The indicator is at the beginning of the green battery

control range

The battery is charged to 20 % (picture 5)

The indicator is in the yellow battery range

The battery must be recharged

21

Figure 7: charging of the EXOTECTOR with the universal charger

CHARGING of the battery block must be carried out as follows:

Measurement range switch in position "OFF".

Connect plug of the charger to the mains supply.

Put charging plug of the charger or the universal charger

into the charging socket of the EXOTECTOR.

The yellow operation LED of the charger lights up, the

EXOTECTOR is recharged for about 8 hours.

After approximately 8 hours the universal charger switches

over to trickle charge. Thus, an overcharge of the NiCdaccumulator is impossible. The green LED of the charger
lights up.
If the EXOTECTOR is not used for a longer period of time, the
EXOTECTOR can be connected to the universal charger in the
charging mode trickle charge. Thus, the EXOTECTOR is always
ready for operation.
If the battery block is always charged in trickle charge mode, it
should be discharged once a month but at least once every
three months to ensure its proper functioning and a long lifespan. If battery blocks are older than three years, their possibly
22

reduced capacity can be increased by carrying out the

described charging/discharging cycle two or three times in
succession. If the device was only used for a short period of
time (one or two hours), in order to maintain the long lifespan
of the NiCd-accumulator it is recommended, not to carry out
the normal full charging every time. By pressing the switch at
the universal charger the charger can be switched to trickle
charge mode at every time within the 8 hours.
It must be observed that a discharged battery block can only be
recharged partially in the charging mode trickle charge, but not
fully recharged. This is on purpose and is achieved by the
impulse trickle charge which is especially used in the GfG
universal charger.
The NiCd-accumulators cannot be overcharged.
If the NiCd-accumulators are treated properly, a lifespan of 3-5
years and more can be achieved.
7.2 Calibration and adjustment
All calibration and adjustment works must be carried out by
trained personnel. In general, these works are carried out by the
GfG service or by authorized persons.
The calibration interval chosen must ensure that the deviation
does not exceed 5 % LEL. Even in the case of deviations of less
than 5 % LEL, the calibration intervals should not exceed 16
weeks.
Calibration means the ascertainment of a measuring deviation
of the device using a test gas. Adjustment means the setting to
the lowest possible measuring deviation.
The test should be carried out as follows:

Position of mechanical zero point, adjustment if necessary

Charging status of the battery, recharging if necessary

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Display using zero gas, adjustment of electrical zero if

necessary
Display using standard test gas 0 to 5 % volume / 0 to 100 %
LEL, adjustment if necessary
Display using standard test gas 0 to 100 % volume,
adjustment if necessary
Alarm release using an alarm test gas, adjustment if
necessary
Checking adjustment time

Position of use
In order to get a high measurement accuracy, the EXOTECTOR
should be calibrated in its normal position of use. The
EXOTECTOR as a handheld device is mainly held in the position 0
to 150, this position should be chosen for calibration and
adjustment proceedings.
Nevertheless, regardless of the chosen position of use for
maintenance, the EXOTECTOR measures and warns in every other
position of use with the indicated accuracy.
7.2.1 Calibration of the mechanical zero
The EXOTECTOR must be switched off and the indicator of the
measurement device must be on the zero point line of the scale.
If the deviation is more than one indicator breadth, the
mechanical zero point must be adjusted. This is carried out by
using the delivered screw driver, turning the "adjustment screwmechanical zero" of the switched-off device until the indicator
of the instrument is identical with the zero point line of the
scale.
If this adjustment is not carried out, the deviation affects the
measurement result and the alarm threshold deviates in
proportion to the mechanically misadjusted range.

24

Like the mechanical zero point the electrical zero point is

identical to the zero point of the scale. The electrical zero point
calibration has to be carried out as follows:

Turn the range key to the position 0 to 100 % volume

The indicator must move into the zero tolerance area
within 30 seconds.
If the indicator exceeds the zero tolerance area, the
measurement chamber must be purged with fresh air for 1
minute in order to remove possibly present residual gases
from the measurement chamber.
If the indicator is still not in the zero tolerance area after
the measurement chamber has been purged. The electrical
zero-point must be adjusted.
The adjustment potentiometers are situated on the left side
of the device. The indicator must be moved to the zero
point line by turning the potentiometer screw "N. P.
volume" with a screw - driver.
After the zero point calibration of the thermal conductivity
range 0 to 100 % volume has been completed, the zero
point calibration of the catalytic combustion range 0 to 5 %
volume. 100 % LEL respectively) can be done in the same
order. For this purpose, the range 0 to 5 % volume (O to 100
% LEL respectively) must be switched on and the zero point
can be adjusted with the adjustment potentiometer "N. P. LEL".
The zero point calibration of the "micro range" (EXOTECTOR
G 634 P) is done by means of the big adjustment switch on
the outside of the device. If the fine adjustment range is
not sufficient, a screwdriver can be used for the adjustment
of the potentiometer "N. P . -LEL". If the potentiometer "N .
P. LEL" in the "micro range" has been changed during the
adjustment of the zero point, a complete adjustment of the
device in the range 0 to 5 % / 0 to 100 % LEL respectively is
necessary.
25

After the zero calibrations of the different ranges have

been completed, the device must be switched off. Now the
zero calibration has been completed.

7.2.3 Sensitivity calibration

Select suitable test gas in air. The concentration of the

selected test gas must exceed the adjusted alarm threshold.
Thus, the acoustic alarm and the optical alarm can be
checked at the same time.
Range
Test gas*
Reference
Display
gas*
0 to 5 % volume 2 % volume
methane
methane

2% volume
methane
0.4 % volume
propane

1.05 % volume
methane

0 to 100 %
100 % volume
volume methane methane

100 % volume
methane

0 to 100 LEL-%
methane

0.4 % volume
propane

24% LEL
propane

2 % volume
methane

40% LEL
methane
0.4 % volume
propane

0100% LEL nnonane

80% LEL nnonane

0.56 % volume
n-nonane
(at= 25oC)
2 % volume
methane

26

22% LEL
methane

75% LEL
nonane

Switch on 0 to 5 % volume (O to 100 % LEL) range. Select suitable

test gas, e.g. 2 % volume methane in synthetic air.
Take in test gas from a gas bag via sampling line by using the

Pump or press the test gas through the pump by means of

a pressurized gas can with a volume flow of 0.5 l/minute In
this case the gas pump does not need to be switched on.

The indicator should show the gas concentration of the test

gas within 20 seconds.

If the device does not show the test gas concentration, the
value must be adjusted at the sensitivity potentiometer
"CAL.-LEL" by means of a screwdriver.
If the value cannot be adjusted by means of the sensitivity
potentiometer, the sensor must be checked or possibly
replaced. Replacement of the sensor must be completed by the
GfG service.
27

Switch on 0 to 100 % volume

Select suitable test gas, e.g. 100 % volume methane.

Turn the range key to the measurement range 0 to 100 %

volume, take in test gas via gas pump or via sampling line
through the pumping set. The volume flow must be approx.
0.5 l/minutes.

The indicator should show the test gas concentration within

20 seconds.
If the device does not show the test gas concentration, the
value must be adjusted at the sensitivity potentiometer "CAL.LEL" by means of a screwdriver.
If the value cannot be adjusted by means of the sensitivity
potentiometer, the sensor must be replaced. Replacement of
the sensor must be completed by the GfG service. The
calibration is complete after the control and the sensitivity
adjustment of the range 0 to 100 % volume (if necessary) have
been carried out.
7.3 Gas alarm thresholds
The EXOTECTOR has an adjustable alarm threshold in the range 0
to 5 % volume (0 to 100 % LEL respectively). The alarm threshold
is factory-set at 1 % volume (20 % LEL respectively). If the gas
concentration exceeds the alarm threshold, an acoustic and
optical alarm is released. This is valid for the two ranges:

0 to 5 % volume (0 to 100 % LEL)

Micro range 0 to 8,000 ppm

Depending on the type of device the alarm is either latching or
volatile. The latching alarm can only be switched off below the
set alarm threshold by pressing the reset switch/charge control
switch shortly. If desired, the alarm threshold can be factory-set
at another value by the GfG service.

28

There is no alarm threshold in the range 0 to 100 % volume. This

is not an error but on purpose, because high gas concentrations
are supposed to be present in the range 0 to 100 % volume.
7.4 Grit and fine dust filter
There is a grit filter in the intake of the EXOTECTOR. The filter
should be checked at least once a week or after it has been used
in a dusty or dirty area. The dust filter protects the flow system
and the pump from soiling to a great extent. The control and
the possible exchange of the grit filter must be done as follows:

The intake (picture 1, position 15) is unscrewed by means of

an allan key (size 3).
The grit filter is checked for dust. The filter must be
replaced, if the color of the filter becomes darker.
If the grit filter is very dirty, the subjacent sintered metal
filter (fine dust filter) must be replaced. The sintered metal
filter can be exchanged after the adjustment screw of the
sintered metal filter has been removed.
After having proceeded as described above, the different
parts must be assembled in reverse order. It must be
ensured that the bulging of the adjustment screw must
show to the sintered metal.

29

7.5 Pump control

An exact measurement can only be accomplished if the gas
pump works accurately and if the suction capacity is sufficient.
A flow indicator (e.g. rotameter) and a vacuum meter are
necessary for a proper control. The minimum pump capacity
must be higher than 0.25 l/minutes and the suction capacity
must come to 8,000 Pa (800 mm WS). The intake is connected
with the testing instrument via a sampling line. The pump is
activated when the measurement range is switched on and
when the pump switch is pressed. The suction line must be
checked if the pump capacity is too low. If the pump capacity is
still too low after the dust filter has been replaced or cleaned,
an inspection by the GfG service is necessary.

30

If there are no measurement devices available for checking the

pump performance, a rough inspection can be carried out
quickly.

Switch the device on using the range switch

Press pump switch

Close intake

You can hear the pump abating (or even stopping)

Pump check is complete

7.6 Maintenance schedule
According to the conditions of use and the company regulations
the shown maintenance schedule should be a suggestion for the
inspections. Maintenance such as interim inspections and main
inspections are to be completed regularly.

Symbols

X:
0:

Check when used daily

Check when stored

31

Z:
H:

Interim check/functional check by authorized

person (includes all checks X/0)
Annual main check/functional check by
authorized person (includes all checks X/O an all
other works).

The user is not allowed to open the device. In case of claims

please contact GfG service.

32

8. Malfunctions
Failure

Cause

Clearing

The indicator does not

move to the zero
Mechanical zero point
misadjusted
when the device is
switched off

Adjust mechanical
zero point line (see
7.2.1)
1.

The indicator does not

move to the zero
Electrical zero point
tolerance field after it misadjusted
has been switched on

2.

Purge with fresh

air
If the indicator
still does not
move to the zero
tolerance field,
the electrical
zero must be
adjusted (see
7.2.2)

After the device has

been switched on in
the range 0.5 %
Purge the
Sampling line is still filled
volume (0 to 100% LEL),
measurement
with gas
the device raises an
chamber
acoustic and optical
alarm
The indicator has moved
Press reset key and
to the alarm threshold
and has raised the alarm cancel the alarm
(heating effect)
Pump does not work

The device raised an

acoustic and optical
alarm after having
been switched on

Intake soiled

Exchange filter, check

intake

Faulty pump

Pump must be
replaced by GfG
service

Battery discharged

Recharge battery
block (see 7.1)

33

Failure

Cause

Clearing

Display reads zero

device is switched on,
the indicator moves to Zero-point misadjusted
the right or left limit
stop
Faulty sensor or sensors

Adjust zero-point (see

7.2.1)
Measurement
chamber must be
replaced

9. Accessories
There are many accessories available for the EXOTECTOR.

Leather case
The leather case serves for transporting the device. It protects
the device from shocks, impacts and soiling.
Special sampling line

34

If measurements have to be taken at inaccessible places, the gas

sample is taken by means of a special sampling line. The
sampling line is made of special antistatic rubber. The sampling
line always contains a built-in dust and humidity filter. The
sampling line is also available with a flow indicator showing the
perfect function of the pump by means of a green section.
There is a 3 m sampling available as well as a 6 m sampling line.
Telescopic probe
The telescopic probe allows to take samples at places which
cannot be reached using a sampling line. The telescopic probe is
made of corrosion resistant steel and has a probe top which
makes the suction of liquid nearly impossible. There is a 1.36 m
telescopic probe available as well as a 1.92 m telescopic probe.
Universal charger
By means of the GfG universal charger NiCd-accumulators with a
nominal charging capacity between 100 mAh and 2 Ah can be
charged. The universal charger is suitable for charging all
battery blocks contained in the gas measurement device of the
GfG (pocket-size devices, handheld devices, and portable
devices) except from the measurement devices Vabotector and
GMA 052-T.
The charger works with a pulsed standard and with trickle
charge. After about 8 hours the charger switches from standard
charge to trickle charge automatically.
Filter
Grit filter: A grit filter is situated in the intake of the EXOTECTOR.
This filter protects the suction line and the electrical pump from
dust and soiling. The functioning of the filter must be checked
at regular intervals. If the filter does not work properly, it must
be replaced.
Fine dust filter: Below the grit filter a sintered metal filter is
situated in the EXOTECTOR. This filter must be cleaned in case of
35

severe soiling of the grit filter. In general, the filter is replaced

by GfG service or authorized personnel.
Special dust and water filter
There is a special dust and water filter in the sampling line. This
filter protects the device from suction of water, humidity, and
dust.
Charcoal filter tubes for the determination of methane or
propane
In manholes and sewers methane (natural gas) as well as propane
(technical gas) can be found. It is not possible to distinguish
between these gases by reading of the EXOTECTOR only.
e GfG charcoal filter tube makes it possible to distinguish
between methane and propane/butane. The distinction is
possible because the GfG charcoal filter tube retains propane
and butane in concentrations up to 15 %, but methane (natural
gas) is almost not retained. The charcoal filter tubes are available
in a pack containing 9 filter tubes and an additional sampling
line.
10. Ordering information
Type of detector
EXOTECTOR G 624 P
Two detection ranges
0 to 5 % volume and 0 to 100 volume-O/o or
(to 1oo % LEL and 0 to 100 % volume
EXOTECTOR G 634 P Three detection ranges
Micro (leak detection), 0 to 5 % volume and 0 to 100 %
volume or
Micro (leak detection), 0 to 100 I/o LEL and 0 to 100 %
volume
For part numbers please contact GfG Instrumentation.

36

The EXOTECTOR is available for numerous gases, e.g. methane,

natural gas, town gas, hydrogen, propane, butane, nonane (fuel
vapors), etc.
Accessories
# Description
1. Universal charger 220 W50HZ (standard and trickle charge)
2. 5-point charger 220 V or 110 V 200/20 mA (standard/trickle
charge)
3. Universal charger for cars (12 V) (standard and trickle charge)
4. Universal charger 110 W6OHz (standard and trickle charge)
5. Universal charger in transport case (12 V)
6. Leather case for G 600 series
7. Telescopic probe CrNi steel 1.36 m, with connection adapter
and 50 cm sampling line
8. Telescopic probe CrNi steel 1.92 m, with connection adapter
and 50 cm sampling line
9. Spare connection adapter with 50 cm sampling line
10. Special sampling line 3 m, antistatic, with filter for particles
and humidity
11. Special sampling line 3 m, antistatic, with filter for particles
and humidity and flow indicator
12. Special sampling line 6 m, antistatic, with filter for particles
and humidity
13. Special sampling line 6 m, antistatic, with filter for particles
and humidity and flow indicator
14. Special water filter
15. Charcoal filter tube for distinction of methane or propane
(pack of 9 each)

37

38

1194 Oak Valley Drive, Suite 20

Ann Arbor, Michigan 48108
United States of America
Phone: (800) 959-0329 or (734) 769-0573
Fax (734) 769-1888
E-mail: info@gfg-inc.com
Website: www.gfg-inc.com
706